2693 version 6
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Repair ferrous metal components using welding processes
Level
4
Credits
10
Purpose
This unit standard covers repair of steel, stainless steel, and cast iron
components by welding, using GMAW, GTAW, MMAW, OAW, and powder
spray processes.
People credited with this unit standard are able to: demonstrate knowledge of
repair welding of ferrous metal components; prepare for repair welding of
ferrous metal components; repair-weld ferrous metal components; and
quality-assure repair welding of ferrous metal components.
Subfield
Mechanical Engineering
Domain
Welding
Status
Registered
Status date
22 May 2009
Date version published
22 May 2009
Planned review date
31 December 2014
Entry information
Recommended: Unit 2676, Weld stainless steel sheet
using the gas tungsten arc welding process; and Unit
2682, Weld steel in the downhand positions to a general
purpose industry standard using the manual metal arc
welding process; or demonstrate equivalent knowledge
and skills.
Accreditation
Evaluation of documentation and visit by NZQA.
Standard setting body (SSB)
Competenz
Accreditation and Moderation Action Plan (AMAP) reference
0013
This AMAP can be accessed at http://www.nzqa.govt.nz/framework/search/index.do.
Special notes
1
This unit standard does not qualify people to determine that welding is the preferred
method of repair, particularly for critical components. A suitably qualified person
such as a welding engineer or metallurgist should directly supervise the repair of
critical components.
 New Zealand Qualifications Authority 2016
2693 version 6
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2
Reference
Health and Safety in Welding. Wellington: Department of Labour, 2006. Available
from http://www.osh.govt.nz.
3
Definitions
Ferrous metals – include carbon and low alloy steels, stainless and heat resistant
steels, austenitic manganese steels, cast iron (grey, ductile, and alloy).
GMAW – Gas Metal Arc Welding.
GTAW – Gas Tungsten Arc Welding.
Industry practice – refers to the safe and sound practices accepted by the fabrication
industry.
MMAW – Manual Metal Arc Welding.
OAW – Oxyacetylene Welding.
Powder spray – refers to a welding method in which a thin layer of metal is fused
onto a base metal.
Safe working practice – refers to formal worksite or company safety policies, or the
practices established by Health and Safety in Welding or similar codes.
Welding procedure – refers to a written work instruction providing all the necessary
technical details for a specific welding application.
Worksite standard – refers to the quality standards and procedures in use at the
particular work site.
Elements and performance criteria
Element 1
Demonstrate knowledge of repair welding of ferrous metal components.
Performance criteria
1.1
Methods of identifying parent metals are described in accordance with worksite
standard.
Range
1.2
methods – workshop tests, identification of component
manufacturer, material analysis;
workshop tests include but are not limited to – button weld test, tab
weld test, spark test, magnet test, resistance to filing test.
Factors influencing the choice of repair method and process are identified, and
their practical implications stated.
Range
factors include – types of failure, possible fabrication of new or
replacement parts, weld type and location, distortion control.
 New Zealand Qualifications Authority 2016
2693 version 6
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Element 2
Prepare for repair welding of ferrous metal components.
Performance criteria
2.1
Work area is assessed for hazards associated with repair welding and all
necessary precautions taken in accordance with safe working practice.
Range
2.2
electric shock, arc and flame radiation, fire, explosion, fumes and
gases, heat, confined space, compressed gas, chemicals from
cleaning methods and from prior service environment of
components.
A welding process is selected and assessed for repair welding.
Range
welding processes include but are not limited to – MMAW, GMAW,
GTAW, OAW, powder spray.
2.3
Equipment is selected and assembled to suit the repair welding process.
2.4
Parent metal is prepared for welding in accordance with welding procedure.
Range
2.5
preparation includes – cleaning, edge preparation, surface
preparation by filing or grinding.
Consumables are selected in accordance with repair welding procedure.
Element 3
Repair-weld ferrous metal components.
Performance criteria
3.1
Safety procedures are followed and personal protective equipment is worn in
accordance with safe working practice.
3.2
Electrodes are stored and handled in accordance with manufacturer’s
specifications.
3.3
Weld metal is deposited in accordance with welding procedure.
Range
3.4
evidence is required of three welding repairs, using steel, stainless
or heat resistant steel, and cast iron; and using a different welding
process for each metal.
Welds are cleaned in accordance with industry practice.
 New Zealand Qualifications Authority 2016
2693 version 6
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Element 4
Quality-assure repair welding of ferrous metal components.
Performance criteria
4.1
Methods of assessing weld quality are identified and the process explained in
accordance with worksite standard.
Range
visual examination, penetrant inspection, magnetic particle
inspection, workshop tests.
4.2
Defective repair welds are identified by visual examination and workshop tests.
4.3
Repair procedure is documented for future traceability in accordance with
worksite standard.
Please note
Providers must be accredited by NZQA, or an inter-institutional body with delegated
authority for quality assurance, before they can report credits from assessment against
unit standards or deliver courses of study leading to that assessment.
Industry Training Organisations must be accredited by NZQA before they can register
credits from assessment against unit standards.
Accredited providers and Industry Training Organisations assessing against unit standards
must engage with the moderation system that applies to those standards.
Accreditation requirements and an outline of the moderation system that applies to this
standard are outlined in the Accreditation and Moderation Action Plan (AMAP). The
AMAP also includes useful information about special requirements for organisations
wishing to develop education and training programmes, such as minimum qualifications for
tutors and assessors, and special resource requirements.
Comments on this unit standard
Please contact Competenz qualifications@competenz.org.nz address if you wish to
suggest changes to the content of this unit standard.
 New Zealand Qualifications Authority 2016